Specifications
| Description | Liters |
|---|
| Transfer case lubricant, drain and refill | 0.50 |
| Description | Nm | Lb - ft | Lb - in |
|---|
| M8 pinion housing studs | 35 | 26 | |
| M8 pinion housing bolts | 35 | 26 | |
| Engine anti-roll restrictor mounting bracket top retaining bolts | 55 | 41 | |
| Engine anti-roll restrictor mounting bracket side retaining bolts | 35 | 26 | |
| Engine anti-roll restrictor mounting bracket bottom retaining nuts | 35 | 26 | |
| Engine anti-roll restrictor mount retaining bolt | 55 | 41 | |
| Transfer case support bracket top retaining bolts | 25 | 18 | |
| Transfer case support bracket bottom retaining bolt | 47 | 35 | |
| Transfer case retaining bolts | 80 | 59 | |
| Transfer case fill plug | 20 | 15 | |
| Exhaust front pipe retaining clamp | 55 | 41 | |
| Catalytic converter to catalytic converter mount bracket retaining bolts | 25 | 18 | |
| Shock absorber and spring assembly securing nuts | 25 | 18 | |
| () On vehicles prior to VIN J25640, if you are re-using fixings, tighten to 90 Nm. |
| () | On vehicles prior to VIN J25640, if you are re-using fixings, tighten to 90 Nm. |
Scheme 1
Scheme 1: Transfer Case - Description & Operation
| Item Number | Description |
|---|
| 1 | Transfer case |
| 2 | Transfer case fill plug |
| 3 | Transfer case retaining bolt |
| 4 | Transfer case air cooling duct |
| 5 | Transfer case Y bracket retaining bolt |
| 6 | Transfer case Y bracket |
| 7 | Engine anti-roll restrictor mounting bracket retaining bolts |
| 8 | Engine anti-roll restrictor mounting bracket |
| 9 | Engine anti-roll restrictor mounting bracket retaining nuts |
| 10 | Companion flange retaining nut |
| 11 | Companion flange |
The transfer case system consists of a power transfer unit, rear driveshaft, coupling device and rear axle. The power transfer unit is a gearbox that attaches to the transaxle. The right hand halfshaft engages to the transfer case link shaft which engages to the differential side gears as in a normal 4x2 application. The transfer case provides power to the driveshaft through a helical gear spline coupled to the transaxle differential case, a helical gear drop (idler gear) and hypoid/helical ring gear assembly and pinion set. Repair of the transfer case is limited to seals and gaskets. If any of the geared components, tapered roller bearings, case cover or internal shafts fail, a new transfer case must be installed. The transfer case is sealed from the transaxle and has its own sump. The transfer case uses SAE 75W140 synthetic gear lubricant. The fill plug is located on the top of the transfer case, under the engine anti roll restrictor mounting bracket.
Scheme 2
Scheme 2: Transfer Case Draining and Filling - General Procedures
Scheme 3
Scheme 4
Scheme 5
Scheme 6
Scheme 7
Scheme 8
Scheme 9
Scheme 10
- Remove the front subframe. Refer to «Front Subframe - 2.0L/2.5L/3.0L»(ref-311840-S31054858822009040700000) article.
- Remove the steering gear heat shield bracket.
- Remove the steering gear heat shield.
- Remove the catalytic converter mount bracket to transfer case retaining bolt.
- Remove the engine anti-roll restrictor bracket side retaining bolts.
- Remove the engine anti-roll restrictor bracket retaining nuts.
- Remove the engine anti-roll restrictor bracket.
- Drain the transfer case fluid. Remove the transfer case pinion housing retaining bolts. Remove the transfer case pinion housing.
- Install a new O-ring seal.
- Install the pinion housing in the transfer case. Install the pinion housing. Install the pinion housing retaining bolts. Tighten M8 bolts to 35 Nm.
- Remove the transfer case fill plug. Using a suitable syringe, add fluid to the transfer case. See «Specifications»(ref-311851-S05753866942009040700000) .
- Install the transfer case fill plug. Tighten to 20 Nm.
- Install the engine anti-roll restrictor bracket. Install the engine anti-roll restrictor bracket top retaining bolts.
- Install the engine anti-roll restrictor bracket nuts.
- Install the engine anti-roll restrictor bracket retaining bolts. Tighten to 35 Nm.
- Tighten the engine anti-roll restrictor bracket nuts. Tighten to 35 Nm.
- Tighten the engine anti-roll restrictor bracket top retaining bolts. Tighten to 55 Nm.
- Install the catalytic converter mount bracket to transfer case retaining bolt.
- Install the steering gear heat shield.
- Install the steering gear heat shield bracket.
- Install the front subframe. Refer to «Front Subframe - 2.0L/2.5L/3.0L»(ref-311840-S31054858822009040700000) article.
